York R123 Operating & Maintenance Manual
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York R123 Operating & Maintenance Manual

York R123 Operating & Maintenance Manual

Millennium series centrifugal liquid chillers with optiview control center for electro-mechanical starter, solid state starter & variable speed drive
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®
MILLENNIUM
CENTRIFUGAL LIQUID CHILLERS
OPERATING & MAINTENANCE
Supersedes: 160.55-O1 (402)
Form 160.55-O1 (604)
MODEL YT (STYLE J)
R123 COOLING ONLY
WITH OPTIVIEW
CONTROL CENTER
™
FOR ELECTRO-MECHANICAL STARTER,
SOLID STATE STARTER & VARIABLE SPEED DRIVE
29509A

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  • Page 1 ® MILLENNIUM CENTRIFUGAL LIQUID CHILLERS OPERATING & MAINTENANCE Supersedes: 160.55-O1 (402) Form 160.55-O1 (604) MODEL YT (STYLE J) R123 COOLING ONLY WITH OPTIVIEW CONTROL CENTER ™ FOR ELECTRO-MECHANICAL STARTER, SOLID STATE STARTER & VARIABLE SPEED DRIVE 29509A...
  • Page 2 FORM 160.55-O1 (604) YORK INTERNATIONAL...
  • Page 3 NOT be installed inside the mi cro pan el. NO external wiring is al lowed to be run through the micro panel. All wir ing must be in ac cor dance with YORK’s pub lished spec i fi ca tions and must be per formed ONLY by qual i fi ed YORK personnel. YORK will not be re spon si ble for dam ag es/problems re sult ing from im prop er con nec tions to the con trols or ap pli ca tion of im prop er con trol sig nals.
  • Page 4 While YORK makes no commitment to update or pro vide current in for ma tion automatically to the manual own er, that in for ma tion, if applicable, can be ob tained by con tact ing the nearest YORK Applied Systems Service ofÞ ce. REFERENCE INSTRUCTIONS DESCRIPTION SOLID STATE STARTER (MOD “A”) –...

  • Page 5: Table Of Contents

    System Operating Procedures ... 124 SECTION System Components Description ... 131 SECTION Operational Maintenance ... 135 SECTION Troubleshooting... 138 SECTION Maintenance ... 144 SECTION Preventive Maintenance ... 152 SECTION OptiSave Energy Analyser Feature ... 154 YORK INTERNATIONAL TABLE OF CONTENTS FORM 160.55-O1 (604)
  • Page 6 FIG. 63 – EVACUATION OF CHILLER ... 145 FIG. 64 – SATURATION CURVE ... 147 FIG. 65 – DIAGRAM - MEGGING MOTOR WINDINGS .. 149 FIG. 66 – MOTOR STATOR TEMPERATURE & INSULATION RESISTANCES ... 150 FORM 160.55-O1 (604) YORK INTERNATIONAL...

  • Page 7: Section 1 Description Of System And Fundamentals Of Operation

    FIG. 1 – MODEL YT MILLENNIUM CHILLER SYSTEM OPERATION DESCRIPTION (SEE FIG. 2) The YORK Model YT Millennium Chiller is commonly ap plied to large air conditioning systems, but may be used on other applications. The chiller consists of an...

  • Page 8: Fig. 2 - Refrigerant Flow-Through Chiller

    OIL COOLER FORM 160.55-O1 (604) PREROTATION VANES (See Detail A) SUCTION COOLER ELIMINATOR LD00924 YORK INTERNATIONAL...

  • Page 9: Section 2 Optiview Control Center

    OPTIVIEW CONTROL CEN TER The YORK OptiView Control Center is a mi cro pro - ces sor based control system for R-11 or R123 cen trif u gal chillers. It controls the leaving chilled liq uid tem per a ture via pre-rotation vane controls and has the abil i ty to limit motor current via control of the pre-ro ta tion vanes.
  • Page 10 The program can be upgraded by download- ing a new program from a Program Card. Program Cards are shirt-pocket-size portable memory stor- age devices available from YORK. Earlier vintage chillers could be equipped with a later Microboard due to service replacement.
  • Page 11 FORM 160.55-O1 (604) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 12: Fig. 3 - Control Center

    Cy cling shut down. The switch must be in this state to re ceive a val id re mote start signal when op er at ing under a re mote con trol source. FORM 160.55-O1 (604) 00134VIP YORK INTERNATIONAL...
  • Page 13 Þ rst login with an appropriate ac cess level. When power is applied to the chiller, the system begins with an Access Level of VIEW. This will allow the user to navi- YORK INTERNATIONAL FORM 160.55-O1 (604) gate to most screens and observe the values displayed there.
  • Page 14 User (page 60) Comms (page 62) Printer (page 64) Sales Order (page 66) Operations (page 68) Diagnostics (Refer to YORK Service Man u al 160.55-M1) History (page 70) History Details (page 72) Security Log (page 73) Security Log Details (page 74)
  • Page 15 Leaving Condenser Liquid Temperature Return Condenser Liquid Temperature Evaporator Refrigerant Temperature Discharge Temperature Oil Temperature Condenser Pressure Condenser Temperature (R11)* Condenser Temperature (R123)* Evaporator Pressure Evaporator Temperature (R11)* Evaporator Temperature (R123)* Oil Sump Pressure Oil Pump Pressure Purge Pressure Refrigerant Level (Future) Drop Leg Refrigerant Temperature *Saturation temperatures are calculated values.

  • Page 16: Fig. 4 - Home Screen

    10 continuous minutes without a keypress. SER VICE: In the event that advanced di ag nos tics are nec es sary, a SER VICE ac cess level has been pro vid ed. FORM 160.55-O1 (604) 00347VIP YORK INTERNATIONAL...
  • Page 17 Warning Reset Access Level Re quired: OP ER A TOR Use of this key acknowledges a warning condition and resets the message display associated with it. YORK INTERNATIONAL FORM 160.55-O1 (604) NAVIGATION System Used to provide additional system information.

  • Page 18: Fig. 5 - System Screen

    If either of the transducers used to cal cu late this dif fer - en tial is out of range, the display Þ eld will show XX.X. % Full Load Amps This displays the percentage of full load amps utilized by the system. FORM 160.55-O1 (604) 00348VIP YORK INTERNATIONAL...
  • Page 19 An a log Remote mode, PWM signal in Digital Remote mode, MicroGateway interface in ISN mode or a locally pro grammed value. PROGRAMMABLE None YORK INTERNATIONAL FORM 160.55-O1 (604) NAVIGATION Home Access Level Re quired: VIEW Causes an instant return to the Home Screen.

  • Page 20: Fig. 6 - Evaporator Screen

    Displays the Leaving Chilled Liquid Tem per a ture at which the chiller will restart after it has shut down due to over-cooling temperature. By default, the chiller will restart at the Leaving Chilled Liquid Tem per a ture Setpoint. FORM 160.55-O1 (604) 00349VIP YORK INTERNATIONAL...
  • Page 21 This value allows the user to adjust the sen si tiv i ty of the Leaving Chilled Liquid Temperature con trol. Service Tech ni cians refer to YORK Service Manual 160.55- Smart Freeze (Off / On) Access Level Re quired: SER VICE This value is only available if the chiller is not in Brine mode.

  • Page 22: Fig. 7 - Condenser Screen

    Indicates whether ß ow is present in the con dens er. Condenser Liquid Pump (Run / Stop) Indicates whether Condenser liquid pump is operat- ing. Refrigerant Level Position Displays the present position of the refrigerant level if this function is enabled. FORM 160.55-O1 (604) 00350VIP0 YORK INTERNATIONAL...
  • Page 23 YORK INTERNATIONAL FORM 160.55-O1 (604) it must be enabled via this toggle before the system will utilize the new, enhanced resolution input. Service Tech- ni cians refer to YORK Ser vice Manual 160.55-M1. NAVIGATION Home Ac cess Level Re quired: VIEW Causes an instant return to the Home Screen.

  • Page 24: Fig. 8 - Purge Screen

    The count will be reset when the chiller starts. Exhaust Window Displayed as 0 to 60 minutes. After a 60 minute bypass at chiller start, the Exhaust Window increments from 0 FORM 160.55-O1 (604) 00351VIP YORK INTERNATIONAL...
  • Page 25 10 to 30 Purges/Hour. Ser- vice Technicians, in SERVICE ac cess level can pro gram this setpoint over a greater range. Service Tech ni cians refer to YORK Service Manual 160.55-M1. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen.

  • Page 26: Fig. 9 - Refrigerant Level Control Screen

    Lower (LED) Is ON when the digital output controlling the Level Low er contact is on. PROGRAMMABLE [Refrigerant Level] Setpoint Service Technicians refer to YORK Service Manual 160.55-M1. [Refrigerant Level Control] Period Service Technicians refer to YORK Service Manual 160.55-M1.
  • Page 27 [Refrigerant Level Control] Proportional Limit Close Service Technicians refer to YORK Service Manual 160.55-M1. [Refrigerant Level Control] Rate Limit Open Service Technicians refer to YORK Service Manual 160.55-M1. [Refrigerant Level Control] Rate Limit Close Service Technicians refer to YORK Service Manual 160.55-M1.

  • Page 28: Fig. 10 - Compressor Screen

    Indicates whether the vanes are in the process of clos ing. Pre-Rotation Vanes Position (Variable Speed Drive only) Access Level Required: SERVICE This value displays the present position of the pre-ro- ta tion vanes as a percentage between 0 and 100%. FORM 160.55-O1 (604) 00483VIP YORK INTERNATIONAL...
  • Page 29 Only available if the chiller is stopped and the system uses a Variable Speed Drive or Hot Gas Bypass con- trol. Moves to the subscreen allowing calibration of the Pre-rotation vanes. Service Technicians refer to YORK Service Manual 160.55-M1. VSD TUNING (Variable Speed Drive only)

  • Page 30: Fig. 11 - Hot Gas Bypass Screen

    In ad- dition, the valve can be manually op er at ed. Requires access level of SERVICE. Ser vice Tech ni cians refer to YORK Service Man u al 160.55-M1 for op- er a tion in struc tions and explanation of all pro gram ma ble setpoints and dis played val ues.
  • Page 31 FORM 160.55-O1 (604) Maximum Open (Flash Memory Card version C.MLM.02.02.xxx and later) Service Technicians refer to YORK Ser vice Man u al 160.55-M1. [Hot Gas Bypass Control] Open (Manual) This key puts the Hot Gas Bypass Control in manual mode and increases the valve position by 5%.

  • Page 32: Fig. 12 - Surge Protection Screen

    Displays the time remaining in the 10-minute “EX- TEND ED RUN” period. During this period, the Pre- rotation vanes are driven closed and “Warning – Surge Protection – Excess Surge Limit” is dis played. Refer to operation under “Count Limit” below. YORK INTERNATIONAL...
  • Page 33 SURGE WINDOW COUNT is less than or equal to the COUNT LIM IT. If the SHUT DOWN YORK INTERNATIONAL FORM 160.55-O1 (604) setpoint is Enabled, and the SURGE WIN DOW COUNT exceeds the COUNT LIMIT at the com ple tion of this period, a safety shutdown is performed and “Surge...
  • Page 34 Access Level Required: ADMIN Allows user to set the Total Surge Count to zero. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen Compressor Access Level Required: VIEW Causes an instant return to the Compressor Screen. YORK INTERNATIONAL...
  • Page 35 FORM 160.55-O1 (604) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 36: Fig. 13 - Pre-Rotation Vanes Calibration Screen

    PROGRAMMABLE Start Calibration This option is hidden after cal i bra tion has start ed. Ser vice Technicians refer to YORK Ser vice Manual 160.55-M1 for an ex pla na tion of this setpoint. Cancel Calibration This option only becomes available after calibration has started.
  • Page 37 FORM 160.55-O1 (604) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 38: Fig. 14 - Vsd Tuning Screen

    Variable Speed Drive. Re quires a login access level of SERVICE. Service Technicians re fer to YORK Service Manual 160.55-M1 for operation instructions and ex pla - na tion of all programmable setpoints and displayed values.
  • Page 39 It will not raise the value above the maximum allowed frequency. YORK INTERNATIONAL FORM 160.55-O1 (604) Decrease This key puts the VSD frequency control into manual mode and decreases the present command frequency by the deÞ...

  • Page 40: Fig. 15 - Oil Sump Screen

    Manual Oil Pump control is disabled (and the button hidden) during system prelube, system run and system coastdown. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen. FORM 160.55-O1 (604) 00356VIP YORK INTERNATIONAL...

  • Page 41: Fig. 16 - Electro-Mechanical Starter Screen

    Re mote mode, MicroGateway in ter face in ISN mode or a lo cal ly pro grammed value. Pulldown Demand Time Left Displays the time remaining in the programmed pull- down period if the value is non-zero. YORK INTERNATIONAL FORM 160.55-O1 (604) 00357VIP PROGRAMMABLE Local Motor Current Limit...

  • Page 42: Fig. 17 - Solid State Starter (Mod A) Screen

    This value will override the Motor Current Limit value during this time period. This function is used to provide energy sav ings following chiller start-up. Pulldown Demand Time Access Level Required: OP ER A TOR YORK INTERNATIONAL...
  • Page 43 Current Unbalance Check (Enabled / Dis abled) Access Level Re quired: SER VICE Allows the user to control whether the logic checks for current unbalance and initiates a shutdown as a result. Service Technicians refer to YORK Service Manual 160.55-M1. NAVIGATION Home Access Level Re quired: VIEW Causes an instant return to the Home Screen.

  • Page 44: Fig. 18 - Solid State Starter (Mod B) Screen

    (as percentage of FLA). When the mo tor cur rent reaches this value, the Pre-rotation Vanes will not be permitted to open fur ther. If the motor rises above this value, the Pre-ro ta tion Vanes will close to reduce the current to this value. YORK INTERNATIONAL...
  • Page 45 Allows the user to enable or disable the Solid State Start er Shorted SCR safety detection. This must never be dis abled unless under advisement of the York Fac- to ry. Service Technicians refer to YORK Service Man u al 160.55-M1. kWH Reset Access Level Required: SER VICE Allows the user to reset the cumulative Kilowatt Hours.

  • Page 46: Fig. 19 - Variable Speed Drive Screen

    Total Power Factor Displays the relationship between the Input Power and the Supply kVA. Voltage Total Harmonic Distortion - L1, L2, L3 Displays the Total Harmonic Distortion (THD) for each of the voltage lines as calculated by the Þ lter. YORK INTERNATIONAL...
  • Page 47 FORM 160.55-O1 (604) kWH Reset Access Level Required: SER VICE Allows the user to reset the cumulative Kilowatt Hours. Service Technicians refer to YORK Ser vice Man u al 160.55-M1. Filter Inhibit (Harmonic Filter installed only) Access Level Required: SERVICE Disable the Þ...
  • Page 48 Card version C.MLM.02.04.xxx (and later) is required for VSD part number 371-03789-xxx (503HP 60Hz; 419 HP 50Hz). Service Tech ni cians refer to YORK Service Manual 160.55-M1 for operation instructions and explanation of all pro gram ma ble setpoints and displayed values.
  • Page 49 If the motor current rises above this value, the pre-rotation vanes will close to reduce the current to this value. YORK INTERNATIONAL FORM 160.55-O1 (604) Pulldown Demand Limit Access Level Required: OP ER A TOR...

  • Page 50: Fig. 21 - Variable Speed Drive Details Screen (Vsd With Part Number 371-02767-Xxx (60 Hz) Or 371-03700-Xxx (50 Hz))

    This screen displays more detailed information per- tain ing to a Variable Speed Drive (VSD). Service Tech ni cians refer to YORK Service Manual 160.55- M1 for op er a tion instructions and explanation of all pro gram ma ble setpoints and displayed values.
  • Page 51 (as a percentage of FLA). When the motor cur rent reaches this value, the pre-rotation vanes will not be permitted to open further. If the motor current YORK INTERNATIONAL FORM 160.55-O1 (604) rises above this value, the pre-rotation vanes will close to reduce the current to this value.

  • Page 52: Fig. 22 - Adaptive Capacity Control Details Screen

    Adaptive Capacity Control (ACC). Requires a login access level of SER- VICE. Service Technicians refer to YORK Service Manual 160.55-M1 for operation instructions and ex pla - na tion of all programmable setpoints and dis played values.
  • Page 53 Mapping a point at these conditions will cause the ACC to make ad just - ments to the command frequency in the future in order YORK INTERNATIONAL FORM 160.55-O1 (604) to pre vent the chiller from operating at the con di tions mapped.
  • Page 54 Phase Rotation Displays the phase rotation detected by the Harmonic Filter (A, B, C or C, B, A) Total Supply kVA Displays the total supply KiloVolt-Amps mea sured by the Harmonic Filter. FORM 160.55-O1 (604) 00363VIP YORK INTERNATIONAL...
  • Page 55 Local Motor Current Limit Access Level Required: OP ER A TOR Allows the user to specify the maximum al lowed mo- YORK INTERNATIONAL FORM 160.55-O1 (604) tor current (as a percentage of FLA). When the motor cur rent reaches this value, the pre-rotation vanes will not be permitted to open further.
  • Page 56 Displays the phase rotation detected by the Harmonic Filter ( A, B, C or C, B, A ) Total Supply KVA Displays the total supply KiloVolt-Amps mea sured by the Harmonic Filter. Baseplate Temperature Displays the temperature of the Harmonic Filter Base- plate. YORK INTERNATIONAL...
  • Page 57 Access Level Required: OP ER A TOR Allows the user to specify the maximum al lowed mo- tor current (as a percentage of FLA). When the motor YORK INTERNATIONAL FORM 160.55-O1 (604) cur rent reaches this value, the pre-rotation vanes will not be permitted to open further.

  • Page 58: Fig. 25 - Setpoints Screen

    10°F and the operator programmed value is 45°F, then the remote device can set the Leaving Chilled Liq uid Tem per a ture setpoint over the range 45.0° - 55.0°F. FORM 160.55-O1 (604) 00364VIP YORK INTERNATIONAL...
  • Page 59 Temperature setpoint. It is programmable over a range of 0°F to 70°F above the setpoint, to a max i mum restart YORK INTERNATIONAL FORM 160.55-O1 (604) value of 80°F. The chiller will au to mat i cal ly re start when this tem per a ture is reached.

  • Page 60: Fig. 26 - Setup Screen

    Microboard Program Jump ers and Program Switches is dis played. A qualiÞ ed Service Technician, follow- ing in struc tions in YORK Service Man u al 160.55-M1, es tab lish es this con Þ g u ra tion per the desired operation.
  • Page 61 Allows a Service Technician to enter the applied com- pressor motor type as either electro-mechanical (EM), Solid State Starter (SSS-Mod A), Solid State starter (SSS – Mod B), Variable Speed Drive-60Hz or Variable Speed Drive-50Hz. Service Technicians refer to YORK Service manual 160.55-M1. Anti-Recycle Access level Required: SERVICE Allows a Service Technician to Enable or Disable the anti-recycle timer.
  • Page 62 Diagnostics Access Level Required: SER VICE Moves to the subscreen allowing limited di ag nos tic ca pa bil i ty while operating. Refer to YORK Service Man u al 160.55-M1 Comms Access Level Required: VIEW Moves to the subscreen allowing con Þ g u ra tion of sys tem communications.
  • Page 63 FORM 160.55-O1 (604) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 64: Fig. 27 - Schedule Screen

    Standard week deÞ ni tion, as de scribed above. Schedule (Enabled / Disabled) Access Level Re quired: OP ER A TOR Allows the user to enable or disable the mon i tor ing func- FORM 160.55-O1 (604) 00365VIP week slot. YORK INTERNATIONAL...
  • Page 65 Select Access Level Required: OPERATOR Places a selection box around a start time for a given day. YORK INTERNATIONAL FORM 160.55-O1 (604) Use ◄ , ► , ▲ or ▼ cursor arrows to place the box around the desired start or stop time for a given day.

  • Page 66: Fig. 28 - User Screen

    This allows the user to specify up to four (4) Custom Password values. Each Password will then re quire a cor- responding User ID and User Level. Service Tech ni cians refer to YORK Service Manual 160.55-M1. Custom User Access Level (4) Access Level Re quired: SERVICE This allows the user to specify up to four (4) Custom User Access Levels.
  • Page 67 FORM 160.55-O1 (604) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 68: Fig. 29 - Comms Screen

    DeÞ ne the number of data bits at which the panel shall com mu ni cate through the modem port. COM 2 Parity Bit(s) DeÞ ne the number of parity bits at which the panel shall com mu ni cate through the modem port. FORM 160.55-O1 (604) 00478VIP YORK INTERNATIONAL...
  • Page 69 DeÞ ne the number of stop bits at which the panel shall com mu ni cate through the modem port. NAVIGATION Home Access Level Re quired: VIEW Causes an instant return to the Home Screen. YORK INTERNATIONAL FORM 160.55-O1 (604) Setup Access Level Re quired: VIEW Return to the Setup Screen.

  • Page 70: Fig. 30 - Printer Screen

    Sales Order screen). A print report is generated upon completion of se lec tion. Print All Histories Access Level Re quired: OP ER A TOR Generate a report of the system data at the time of all stored shutdowns. FORM 160.55-O1 (604) 00368VIP YORK INTERNATIONAL...
  • Page 71 FORM 160.55-O1 (604) NAVIGATION Home Access Level Re quired: VIEW Causes an instant return to the Home Screen. Setup Access Level Re quired: VIEW Return to the Setup Screen. YORK INTERNATIONAL...

  • Page 72: Fig. 31 - Sales Order Screen

    Service Tech ni cian. Entry in struc tions are included in the YORK Ser vice Manual 160.55-M1. The remainder of the values are entered at the YORK Factory during the man u fac tur ing of the chill er.
  • Page 73 FORM 160.55-O1 (604) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 74: Fig. 32 - Operations Screen

    Þ rst number. Although the label and number can be changed appro- priately, the default for this entry is “York Intl North American Toll Free Number 1-800-861-1001”. The Local service phone number is displayed as the second number.
  • Page 75 FORM 160.55-O1 (604) NAVIGATION Home Access Level Re quired: VIEW Causes an instant return to the Home Screen. Setup Access Level Re quired: VIEW Return to the Setup Screen. YORK INTERNATIONAL...

  • Page 76: Fig. 33 - History Screen

    Causes an instant return to the Home Screen. View Details Access Level Required: VIEW Causes a move to a subscreen containing the value of select chiller parameters at the time of the associated shutdown. FORM 160.55-O1 (604) 00565VIP YORK INTERNATIONAL...
  • Page 77 (Flash memory Card version C.MLM.02.01 or later) Access Level required: VIEW Causes a move to a sub-screen allowing the user to view the Custom Setup Screen. YORK INTERNATIONAL FORM 160.55-O1 (604) Security Log (Flash Memory Card version C.MLM.02.03.xxx and lat er)

  • Page 78: Fig. 34 - History Details Screen

    This generates a report listing the status of the chiller parameters at the time of the selected shut down. NAVIGATION Home Access Level Re quired: VIEW Causes an instant return to the Home Screen. History Access Level Required: VIEW Causes a return to the History Screen. YORK INTERNATIONAL...

  • Page 79: Fig. 35 - Security Log Screen

    1. Multiple pages are necessary to dis play all 75 changes. Not all setpoints are logged. Ser vice technicians refer to list in YORK Service Manual 160.55-M1. Requires a login access level of SER VICE.

  • Page 80: Fig. 36 - Security Log Details Screen

    Displays the value entered at the time of the setpoint change. PROGRAMMABLE Print Generates a report of change parameters displayed on this screen. NAVIGATION Home Access Level Re quired: SERVICE Causes an instant return to the Home Screen. YORK INTERNATIONAL...
  • Page 81 Access Level Required: SERVICE Causes an instant return to the Security Log Screen. View Details Access Level Required: SERVICE Causes a move to a sub-screen containing the details of the setpoint change selected with the Log Entry key. YORK INTERNATIONAL...

  • Page 82: Fig. 37 - Trend Screen

    Upon restoration of power, the last screen of data that was collected will be displayed on the trending screen. The START key must be pressed to initiate a new trend screen. FORM 160.55-O1 (604) 00480VIP YORK INTERNATIONAL...
  • Page 83 Allows the user to display all trended data points si mul - ta neous ly or select a single trended data point for dis play, hiding the other data points. Selections are ALL DATA or DATA POINT X (1-6). YORK INTERNATIONAL FORM 160.55-O1 (604) Print (Flash Memory Card version C.MLM.02.02.xxx...

  • Page 84: Fig. 38 - Trend Setup Screen

    / 60 = full screen hours full screen hours / 24 = full screen days 3. Decide if the resultant sample interval and full screen display meet the requirements. If not, select a dif- fer ent sample interval. FORM 160.55-O1 (604) 00481VIP YORK INTERNATIONAL...
  • Page 85 Access Level Required: OPERATOR Only displayed if the associated slot number is not zero. This is the maximum value displayed for the Y-Axis. YORK INTERNATIONAL FORM 160.55-O1 (604) Se lect ing a parameter for a Data Point sets this to the de fault value, which is the highest value allowed for that pa ram e ter.

  • Page 86: Fig. 39 - Advanced Trend Setup Screen

    While waiting for the trig gers to start or stop data collection, a status message is displayed in the upper right corner of the TREND Screen describing the pending action. DISPLAY ONLY None YORK INTERNATIONAL...
  • Page 87 If the Trigger Action is set to Stop, data collection will stop after the Triggers evaluate as true and the delay timer has elapsed. YORK INTERNATIONAL FORM 160.55-O1 (604) Primary to Secondary Operator Access Level Required: OPERATOR...

  • Page 88: Fig. 40 - Common Slots Screen

    Access Level Required: OPERATOR Generates a list of the slot numbers of the available parameters. NAVIGATION Home Causes an instant return to the Home Screen. Trend Setup Causes a return to the Trend Setup Screen. FORM 160.55-O1 (604) 00374VIP YORK INTERNATIONAL...

  • Page 89: Fig. 41 - Custom View Screen

    DISPLAY ONLY None PROGRAMMABLE Print Access Level Required: VIEW YORK INTERNATIONAL CUSTOM VIEW SCREEN This generates a listing of the parameters displayed on this screen. NAVIGATION Home Access Level Required: VIEW Causes an instant return to the Home Screen.

  • Page 90: Fig. 42 - Custom View Setup Screen

    10 parameters for display on the Custom View Screen. Requires a login ac cess level of SER- VICE. Ser vice Technicians refer to YORK Ser vice Manual 160.55-M1 for operation in struc tions and ex pla - na tion of all programmable setpoints and dis played values.
  • Page 91 1537 Oil: Sump Temperature 1538 Oil Pump: Control Mode 1539 Oil Pump: Is Pump On 1540 Oil Pump: Manual Time Left YORK INTERNATIONAL FORM 160.55-O1 (604) SLOT DESCRIPTION 1792 Leaving Chilled Liquid: Temperature 1793 Leaving Chilled Liquid: Temperature Differential 1794...
  • Page 92 Filter: Is Filter Running 2864 Filter: Is Precharge Contactor Closed 2865 Filter: Is Supply Contactor Closed 2866 Filter: Phase Rotation 2867 Filter: Motor HP 2868 Filter: Supply KVA 2869 Filter: Total Power Factor 2870 Filter: DC Bus Voltage YORK INTERNATIONAL...
  • Page 93 Filter: L2 Total De mand Distortion 2889 Filter: L3 Total De mand Distortion 2890 Filter: Maximum Total Harmonic Distortion 2891 Filter: Maximum Total Demand Distortion YORK INTERNATIONAL FORM 160.55-O1 (604) SLOT DESCRIPTION 8205 Refrigerant Level: Is Control Enabled 8206 Refrigerant Level: Position...
  • Page 94 The chiller is running, controlling the Leaving Chilled Liq uid to the Leaving Chilled Liquid Temperature Setpoint. There are no system conditions inhibiting this operation. FORM 160.55-O1 (604) Motor Current (%FLA) Electro-Me chan i cal/ Ser vice Mode Solid state starter YORK INTERNATIONAL...
  • Page 95 The Safety threshold in Brine ap pli ca tions is determined by the Brine solution and is de ter mined by the YORK Factory. While this condition is in effect, the Pre-rotation Vanes are inhibited from fur ther open-...
  • Page 96 Warning Threshold (PSIA) Reset Thresh old (PSIA) Water Brine Wa ter 0.1 >Safety Setpoint R123 0.1 >Safety Setpoint “WARNING – VANES UNCALIBRATED – FIXED SPEED” The Compressor Motor Variable Speed Drive (VSD) is operating Fixed Speed (full speed) mode because the Pre-rotation Vanes position potentiometer calibration has not been performed.
  • Page 97 Safety shut down when displayed in red characters. The OptiView Control Center is conÞ gured for auto-restart or manual restart after power failure by a qualiÞ ed Ser- vice Technician following in struc tions in YORK Ser vice Manual 160.55-M1.
  • Page 98 LED’s on the respective device illuminate to iden ti fy the spe ciÞ c fault that has occurred. Refer to YORK Manual 160.46-OM3.1 for details of Mod “A” Solid State Start er initiated shut downs and 160.55-M1 for CM-2 initiated shut downs.

  • Page 99: Solid State Starter Cycling Shutdown Messages

    OptiView Control Cen ter has not yet received the cause of the fault from YORK INTERNATIONAL the LCSSS, via the serial communications link. The LCSSS shuts down the chiller by opening the Motor...
  • Page 100 7L-35 to 260A, 14L-65 to 510A, 26L-125 to 850A and 33L-215 to 1050A. The chiller will be permitted to start when the jumpers are conÞ gured correctly. Refer to YORK Starter service manual 160.00-O2 for valid jump er con Þ g u ra tions. “LCSSS – PHASE LOCKED LOOP”...
  • Page 101 Ser vice and troubleshooting information is con tained in YORK Manual 160.00-M1. “VSD SHUTDOWN – REQUESTING FAULT DATA” The VSD has shut down the chiller and the OptiView Control Cen ter has not yet received the cause of the fault from the VSD, via the serial communications link.
  • Page 102 ß ow. At this point, we sug gest you back- ß ush the heat-exchanger by re vers ing the two rub ber hoses which supply condenser water to-from the heat-exchanger. If the rust cannot be back-ß ushed, the heat-exchanger might have to be re placed. YORK INTERNATIONAL...
  • Page 103 This allows the VSD to properly scale the out put current. If the Jumper conÞ guration is invalid, a shut down is performed and this message is generated. Re fer to YORK VSD Service manual 160.00-M1. “VSD – LOW PHASE A INVERTER HEATSINK TEMPERATURE”...
  • Page 104 “HARMONIC FILTER – DC BUS VOLTAGE IM- BAL ANCE” The Þ lter DC link is Þ ltered by large, electrolytic ca- pac i tors, rated for 450VDC. These capacitors are wired YORK INTERNATIONAL...
  • Page 105 Brine solu- tion. The Brine shutdown thresh old is pro grammed at the YORK Factory. It should not be changed by any one other than a qualiÞ ed Service Technician fol low ing instructions in YORK Service Manual 160.55-M1.
  • Page 106 The chiller can be restarted after a Service Technician performs a special reset preset proce- dure contained in YORK Service Manual 160.55-M1. “CONDENSER – PRESSURE TRANSDUCER OUT OF RANGE” The Condenser Pressure Transducer is indicating a pres sure that is >35.3 PSIA.
  • Page 107 Safety shutdown when displayed in red char ac ters. The OptiView Control center is conÞ gured for auto-restart or manual restart after power failure by a qualiÞ ed Ser- vice tech ni cian following instructions in YORK Service Manual 160.55-M1. “MOTOR OR STARTER – CURRENT IMBALANCE”...
  • Page 108 In certain applications, local power line conditions could interfere with the open SCR detection technique. This requires a qualiÞ ed Ser- vice Technician to disable this check. Refer to YORK Ser vice Manual 160.55-M1. “LCSSS – PHASE (X) OPEN SCR”...
  • Page 109 Stop-re set position (O). “VSD – HIGH PHASE B INVERTER HEATSINK TEMPERATURE” (Style D VSD) See Phase A message above. YORK INTERNATIONAL FORM 160.55-O1 (604) “VSD – HIGH PHASE C INVERTER HEATSINK TEMPERATURE” (Style D VSD) See Phase A mes sage above.

  • Page 110: Fig. 45 - Sample Printout (Setpoints)

    (15 or 30 min de mand)”. In the Filter option sup plied by YORK, the displayed TDD is the total RMS val ue of all the har mon ic cur rent sup plied by the main power to the VSD di vid ed by the chiller Full Load Amps, in per cent.
  • Page 111 FORM 160.55-O1 (604) THIS PAGE INTENTIONALLY LEFT BLANK TO MAINTAIN FORMAT YORK INTERNATIONAL...

  • Page 112: Section 3 Printers

    Printers FORM 160.55-O1 (604) SECTION 3 PRINTERS 23887A OKIDATA MICROLINE 184 23889A WEIGH-TRONIX 00085VIP SEIKO DPU-414 FIG. 43 – PRINTERS YORK INTERNATIONAL...
  • Page 113 C.MLM.02.03.xxx and later) • Figure 50 - Trend (Flash Memory Card version C.MLM.02.02.xxx and later) • Figure 51 - Custom Screen YORK INTERNATIONAL FORM 160.55-O1 (604) • Figure 52 - Adap tive Capacity Control New Map point Report • Figure 53 - Adaptive Capacity Control...
  • Page 114 DSR active Buffer threshold 32 bytes Busy signal 200ms DTR space after power on (-) Low when busy 1200 Baud* 1200 Baud* 1200 Baud* no parity Pin 20 & pin 11 act as busy line 1200 Baud* 1200 Baud* YORK INTERNATIONAL...
  • Page 115 Parity condition - odd 3-4 = on Busy control - H/W busy 3-5 = on Baud rate select - 1200* YORK INTERNATIONAL FORM 160.55-O1 (604) 3-6 = off Baud rate select - 1200* 3-7 = on Baud rate select - 1200*...

  • Page 116: Fig. 44 - Sample Printout (Status)

    Printers YORK UPDATE CHILLER ID YORK Update Chiller ID ------------------------------------------------------------------------- (c) 1997 – 2001 YORK INTERNATIONAL CORPORATION SYSTEM RUN LEAVING CHILLED LIQUID CONTROL WARNING – PURGE – FLOAT SWITCH ERROR [List all warnings presently active] Controls C.MLM.02.03.102 Run Time 0 Days...
  • Page 117 L3 RMS Filter Current L1 RMS Supply Current L2 RMS Supply Current L3 RMS Supply Current L1 Voltage Total Harmonic Distortion FIG. 44 – CONTINUED YORK INTERNATIONAL = 190 A = 88 ~F = 89 ~F = 75 ~F = 75 %...
  • Page 118 Printers YORK SETPOINTS CHILLER ID ------------------------------------------------------------------------- © 1997 - 1999 YORK INTERNATIONAL COR PO - RA TION Mon 21 jun 1999 1:27 :39 PM Software Versions ------------------------------------------------------------------------- Controls = C.MLM.02.03.102 BIOS Kernel GPIC Ext I/O [Skip if Hot Gas Disabled]...

  • Page 119: Fig. 46 - Sample Printout (Schedule)

    Motor HP FIG. 45 – CONTINUED YORK INTERNATIONAL YORK SCHEDULE 100 % 100 % CHILLER ID 0 Min © 1997 - 1999 YORK international corporation mon 21 jun 1999 schedule 100 % Standard Schedule 100 % 100 % --------------------------------------------------------------------------- 100 %...

  • Page 120: Fig. 47 - Sample Printout (Sales Order)

    Printers YORK SALES ORDER CHILLER ID © 1997 - 1999 YORK INTERNATIONAL COR PO RA TION Mon 21 jun 1999 1:28:46 PM Order Information --------------------------------------------------------------------------- Commissioning date Job Name Job Location Model Number YORK Order Number Panel Serial Number Chiller Serial Number...

  • Page 121: Fig. 48 - Sample Printout (History)

    YORK HISTORY 1 CHILLER ID --------------------------------------------------------------------------- © 1997 - 1999 YORK INTERNATIONAL COR PO RA TION MSYSTEM READY TO START LCSSS – LOGIC BOARD POWER SUPPLY [List any warnings that were active at the time of shutdown] Controls C.MLM.02.03.102 Run Time 0 Days 2 Hr 59 Min...

  • Page 122: Fig. 49 - Sample Printout (Security Log)

    L2 Supply Current Total Demand Distortion FIG. 48 – CONTINUED YORK SETPOINT CHANGE LOG CHILLER ID 163 © 1997 – 2000 YORK INTERNATIONAL COR PO RA TION = Off Mon 09 Oct 2000 3:33:47 PM = 0 % = 0 %...

  • Page 123: Fig. 50 - Sample Printout (Trend)

    YORK TREND CHILLER ID 163 © 1997 – 2000 YORK INTERNATIONAL COR PO RA TION Mon 09 Oct 2000 3:33:47 PM Data 1: Leaving Chilled Liquid Temperature Data 2: Return Chilled Liquid Temperature Data 3: Evaporator Pressure Data 4: Leaving Condenser Liquid Temperature...

  • Page 124: Section 4 System Operating Procedures

    When the start switch is en er gized the Control Cen ter is placed in an op er at ing mode and any mal func tion will be not ed by mes sag es on the OptiView Con trol Center. (See Fig. 3) FORM 160.55-O1 (604) YORK INTERNATIONAL...
  • Page 125 Condenser Water Tem per a ture Con trol The YORK Millennium chiller is de signed to use less pow er by tak ing ad van tage of lower than design tem per a tures that are nat u ral ly produced by cooling tow ers through out the op er at ing year.

  • Page 126: Fig. 54 - Operation Sequence & Timing Diagram (Electro-Mechanical & Solid State Starter Applications)

    FIVE SUCCESSIVE RESTARTS HAVE NOT OCCURRED) FORM 160.55-O1 (604) ENERGIZE (OPEN) VENT LINE SOLENOID 150 SEC. (2.5 MIN.) 1800 (30) RESTART LD04643 (OPEN) VENT 150 SEC. (2.5 MIN.) 1800 (30) RESTART (ONLY AFTER THE FIFTH SUCCESSIVE RESTART) LD04644 YORK INTERNATIONAL...

  • Page 127: Fig. 56 - Minimum Entering Condensing Water Temperature

    PRINT key on the Keypad or automatically using the Data Logger feature. FIG. 57 – LIQUID CHILLER LOG SHEETS YORK INTERNATIONAL CHECKING OP ER A TION During operation, the fol low ing con di tions should be periodically checked: 1.
  • Page 128 4°F.) 9. Verify proper water treatment. 10. If the chiller is con trolled by a YORK Variable Speed Drive, check the op er at ing lights on the logic sec tion. (Re fer to 160.00-O1) 11.

  • Page 129: Fig. 58 - Turboguard Purge Unit

    6. Perform chemical anal y sis of system. Every Two Years 1. If unit is equipped with SSS or VSD, ß ush cool ing circuit and replace with new coolant solution, YORK Part # 013-02987-000. NEED FOR PURGING THE SYSTEM...
  • Page 130 Then press and release the “OIL PUMP” key to stop operation of the oil pump. If the water sys tems were drained, Þ ll the con dens er water cir cuit and chilled liquid circuit. YORK INTERNATIONAL...

  • Page 131: Section 5 System Components Description

    LUBRICATION SYS TEM - YORK lu bri cat ing oil is force fed to all bear ings and Þ ltered by an ex ter - nal ly mounted 15 mi cron replaceable car tridge oil Þ...

  • Page 132: Fig. 59 - Schematic Drawing (Yt) Compressor Lubrication System

    System Components De scrip tion FORM 160.55-O1 (604) FIG. 59 – SCHEMATIC DRAWING – (YT) COM PRES SOR LUBRICATION SYSTEM LD03278 YORK INTERNATIONAL...
  • Page 133 The reservoir, lo cat ed on YORK INTERNATIONAL FORM 160.55-O1 (604) the top of the compressor, al lows the oil to be dis trib ut ed through the pas sag es by grav i ty ß...
  • Page 134 YORK INTERNATIONAL...

  • Page 135: Section 6 Operational Maintenance

    - dra tor. FIG. 60 – OIL RETURN SYSTEM YORK INTERNATIONAL SECTION 6 OIL RETURN SYSTEM 2. Remove the de hy dra tor as follows: Refer to Fig.

  • Page 136: Fig. 61 - Assembly Of Dehydrator

    Operational Maintenance FORM 160.55-O1 (604) LD00470 FIG. 61 – ASSEMBLY OF DEHYDRATOR YORK INTERNATIONAL...

  • Page 137: Fig. 62 - Charging Oil Reservoir With Oil

    The nominal oil charge for the com pres sor is: 10 gal. “B” and “C” com pres sor; 15 gal. “E” and “F’ com pres sor. New oil YORK Refrigeration Type “C” must be used in the centrifugal compressor. Since oil absorbs mois ture when ex posed to the atmosphere it should be kept tight ly capped until used.

  • Page 138: Section 7 Troubleshooting

    Chilled water 4°F below chilled setpoint water setpoint 5.43 PSIA 5.42 PSIA Set to Job Spec. Set to Job Spec. 20 PSID 15 PSID 15 PSIG 9 PSIG 220°F 219°F 180°F 179°F 8.29VDC 7.84VDC 8.29VDC 7.84VDC YORK INTERNATIONAL...
  • Page 139 Auto restart plug is removed To restart, press compressor switch to STOP/ on Microboard. RESET position and then to START position. YORK INTERNATIONAL START-UP OF SYSTEM AFTER SHUTDOWN System load is less than minimum capacity. System load is less than minimum capacity.
  • Page 140 (min. system operating temp. = 32°F) SSS Logic Board SSS Logic Board FORM 160.55-O1 (604) GOVERNING CONTROL FUNCTION OPERATING POINT ON RISE ON FALL 60 PSID 59 PSID 71.0°F 55°F 30.0°F 29.9°F See legend on wiring diagram. See Section 2. YORK INTERNATIONAL...
  • Page 141 Chiller will automatically restart when all phases of line voltage increase to the minimum required starting level. Press STOP/RESET switch and then START switch. YORK INTERNATIONAL FORM 160.55-O1 (604) PROBABLE CAUSE AND SERVICE REQUIRED This Shutdown is provided to check on Oil pressure Transducers for failure in the high state.
  • Page 142 (on condenser shell in front of purge unit). Drain the oil from the compressor and charge new oil into the compressor. (See “Oil Charging Procedure”, page 129.) Replace oil heater. YORK INTERNATIONAL...
  • Page 143 12. SYMPTOM: IMPROPER PURGE UNIT OPERATION Purge unit not purging and air is present in the unit. Purge unit purging air and refrigerant YORK INTERNATIONAL POSSIBLE CAUSE High oil pressure. Transducer defective. Relief valve is misadjusted. Misalignment of pump or piping.

  • Page 144: Section 8 Maintenance

    (by means of soap test or leak de tec tor) and re paired. 5. When absolute tight ness of the sys tem has been es- tab lished, blow the mixture of ni tro gen and re frig - er ant through the charg ing valve. FORM 160.55-O1 (604) YORK INTERNATIONAL...

  • Page 145: Fig. 63 - Evacuation Of Chiller

    * One standard atmosphere = 14.696 PSIA = 760 mm Hg. absolute pressure at 32°F = 29.921 inches Hg. absolute at 32°F TABLE 3 – SYSTEM PRESSURES FIG. 63 – EVACUATION OF CHILLER YORK INTERNATIONAL ABSOLUTE MILLIMETERS OF PSIA MICRONS MERCURY (HG) 14.696...
  • Page 146 When this Þ nal va por iza tion has taken place the pressure and temperature will con tin ue to drop until eventually a tem per a ture of 35°F or a pressure of 5mm Hg. is reached. YORK INTERNATIONAL...

  • Page 147: Fig. 64 - Saturation Curve

    YORK INTERNATIONAL it to at mo spher ic pressure and the indicator tem per a ture will re turn to approximately am bi ent tem per a ture. Close off the system again, and start the second evac u a tion.
  • Page 148 2. If readings fall below shaded area, remove ex ter nal leads from motor and repeat test. Motor is to be megged with the starter at ambient temperature after 24 hours of idle stand by. FORM 160.55-O1 (604) YORK INTERNATIONAL...

  • Page 149: Fig. 65 - Diagram - Megging Motor Windings

    Trouble which may be due to fouled tubes is indicated YORK INTERNATIONAL FORM 160.55-O1 (604) when, over a period of time, the cool ing ca pac i ty de-...

  • Page 150: Fig. 66 - Motor Stator Temperature

    Maintenance FORM 160.55-O1 (604) LD00476 TEMPERATURE – °F FIG. 66 – MOTOR STATOR TEMPERATURE AND INSULATION RE SIS TANC ES YORK INTERNATIONAL...
  • Page 151 In many major cities, com mer cial organizations now of fer a spe cial ized ser vice of acid cleaning coolers and condensers. If acid cleaning is required, YORK rec om mends the use of this type of or ga ni za tion. The...

  • Page 152: Section 9 Preventive Maintenance

    Þ lter el e ment is in stalled, notify the nearest YORK of Þ ce to re quest the pres ence of a YORK Ser vice Tech ni cian.
  • Page 153 2. It is im por tant that the fac to ry set tings of controls (op er a tion and safety) not be changed. If the set tings are changed with out YORK’s ap prov al the war ran ty will be jeop ar dized.

  • Page 154: Section 10 Optisave Energy Analyser Feature

    C.MLM.02.05.xxx (and later) and C.OPT.02.05.301 (and later). It is not operational until enabled using a special procedure. A complete descrip- tion and all required installation, enable and setup in- formation is contained in YORK Service Information Letter SI0068. FORM 160.55-O1 (604) YORK INTERNATIONAL...
  • Page 155 FORM 160.55-O1 (604) NOTES YORK INTERNATIONAL...
  • Page 156 800-861-1001 P.O. Box 1592, York, Pennsylvania USA 17405-1592 Subject to change without notice. Printed in USA Copyright © by York International Corporation 2004 www.york.com ALL RIGHTS RESERVED Form 160.55-O1 (604) Supersedes: 160.55-O1 (402)

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